Speaker enclosure and mounting method for isolating and insulating faceplate and heavy speakers from surrounding mounting surface

ABSTRACT

A speaker enclosure ( 10 ) comprising a speaker box ( 12 ) having an opening ( 27 ) and adapted for mounting within a wall ( 20 ) upon a wall stud ( 22 ); a compressible gasket ( 14 ) affixed about the box opening ( 27 ); a faceplate ( 16 ); and a plurality of independently adjustable coupling mechanisms ( 18 ) for coupling the faceplate ( 16 ) with the box ( 12 ). The protruding, uncompressed gasket ( 14 ) is compressed by the faceplate ( 16 ) and the coupling mechanisms ( 18 ), which may be independently adjusted to provide an optimum and substantially uniform degree of separation between faceplate ( 16 ) and wall ( 20 ), thereby reducing distortion, vibration, and damage due to undesirable contact therebetween. A spring ( 160 ) is provided to prevent over-compression of the gasket ( 14 ) due to heavy or low frequency speakers, thereby facilitating maintaining the uniform degree of separation; and a spacer ( 162 ) is provided to maintain the spring ( 160 ) in its operating position.

RELATED APPLICATIONS

[0001] The present application is a continuation and claims prioritybenefit of a copending U.S. patent application titled SPEAKER ENCLOSUREAND MOUNTING METHOD FOR ISOLATING AND INSULATING FACEPLATE AND HEAVYSPEAKERS FROM SURROUNDING MOUNTING SURFACE, Ser. No. 10/058,598, FiledJan. 28, 2002. The identified copending patent application is herebyincorporated by reference into the present application.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to speaker enclosures or cabinetsrecessedly mounted beneath a surface or within a structure. Moreparticularly, the invention relates to a speaker enclosure adapted forin-wall mounting and having a suspending or isolating and insulatinggasket, a spring, and a spacer providing an optimum or desirable degreeof uniform separation between the enclosure faceplate and the wall inwhich the enclosure is mounted so as to prevent sound distortion andwall damage due to improper installation or vibrations.

[0004] 2. Description of the Prior Art

[0005] Those with skill in the art of home theater systems and speakerenclosures or cabinets will appreciate that a number of strategicallyplaced speakers are often desirable in order to produce the best sound.This is true, for example, in home theater systems employing left andright main, left and right surround, center, and sub-woofer speakergroupings, with each such grouping typically comprising a variety ofindividual specialized speakers, such as high-range “tweeters”,mid-rangers, and low-range “woofers”. Often, it is desirable that atleast some of the speakers be placed upon shelves or otherwise raised soas to minimize sound absorption and interference, tripping hazards, andaesthetic disappeal associated with floor-placed speakers. As will alsobe appreciated, speaker sound quality is directly related to the weightof the speaker magnet, thus many audiophiles insist on increasinglyheavier speakers.

[0006] A well-known solution to strategic and aesthetic speakerplacement is wall-or ceiling-mounting by cutting holes in drywall,wallboard, or other building material to receive and hold eachindividual speaker. Unfortunately, the speakers are typically mountedupon or in contact with the drywall, resulting in drywall cracks orother failure due to vibrations transmitted by the operational speakers.Furthermore, direct speaker-to-drywall contact can result in absorption,interference, or other undesirable sound distortion.

[0007] Another solution is to place the speakers within an enclosure andmount the enclosure to the wall or ceiling. Such enclosures aretypically designed to enhance speaker performance by minimizing unwantedvibrations and optimizing air flow to the speakers. Unfortunately, anenclosure and its speakers, weighing a combined thirty or more pounds,can cause the mounting surface to bow or fail, again resulting indrywall cracks or failure and possibly allowing the enclosure to fall.This is of particular concern where relatively thin drywall or otherbuilding materials have been used to save costs. Furthermore, adjacentwall and ceiling structures can cause undesirable sound distortion orvibrations and are subject to damage when transmitted speaker-generatedvibrations reach certain magnitudes or frequencies. Such vibration canalso lead to a loosening and separation of the enclosure mount from themounting surface.

[0008] Some of the above-described problems can be solved by mountingspeaker enclosures within walls or ceilings rather than to theirsurfaces. That is, rear and side portions of an enclosure are recessedwithin the wall, and preferably coupled with one or more wall studs, sothat only a flush-mounted faceplate protrudes and is seen, with thespeakers being mounted to an interior surface of the faceplate.Unfortunately, though the enclosure may be mounted to wall studs,contact between the faceplate and drywall can still cause bowing,cracking or failure thereof, particularly where the faceplate isovertightened thereupon during installation. Furthermore, even thoughthe faceplate does not depend directly from the drywall, speakervibrations can still be transmitted from the enclosure via the mountingstuds to the drywall, which, again, may cause cracking, sounddistortion, or other undesirable effects.

[0009] Additionally, even where a compressible material, such as, forexample, a tubular gasket, is used to insulate or isolate the faceplatefrom the drywall, a heavy or low frequency speaker, such as a basswoofer or sub-woofer, can cause some or all portions of the compressiblematerial to over-compress or to compress unevenly. Typically, due to thesubstantial weight or low frequency of such speakers, a bottom portionof the compressible material compresses to a far greater degree than atop portion thereof, thereby undesirably causing the faceplate to appearunevenly mounted upon the drywall, and potentially causing the faceplateto continually or intermittently physically contact the drywall at ornear the over-compressed bottom portion of the compressible material,resulting in the aforementioned damage and acoustic problems.

[0010] Due to the above-identified and other problems in the art, a needexists for an improved speaker enclosure and mounting method.

SUMMARY OF THE INVENTION

[0011] The speaker enclosure of the present invention overcomes theabove-identified and other problems in the art to provide a simple andinexpensive enclosure and mounting method for suspending or isolatingand insulating the faceplate and speakers from the mounting wall,thereby reducing distortion, vibration, and damage due to undesirablecontact and transmission of speaker vibrations. Specifically, thepresent invention comprises a speaker enclosure adapted for in-wallmounting and having a heavy duty compressible rubber gasket, preferablyincluding a collapsible tubular air chamber or pocket, interposedbetween faceplate and speaker box to prevent overtightening of thefaceplate to the drywall and thereby provide an optimum or desirabledegree of contact separation and sound insulation.

[0012] The preferred enclosure comprises a speaker box presenting anaccess opening and adapted for mounting upon one or more wall studs anddimensioned so as to fit between exterior and interior wall surfaces; anisolating and insulating gasket affixed about a perimeter of the boxopening; a faceplate to which the speakers are mounted; and a pluralityof independently adjustable threaded coupling mechanisms for couplingthe faceplate with the box. The speaker box is mounted so that theuncompressed gasket protrudes beyond the drywall surface, and provides,when compressed, an optimum or desired degree of uniform separationbetween faceplate and drywall. The insulating gasket is further able toabsorb speaker-generated vibrations that might otherwise be transmittedvia the wall studs to cause sound distortion or damage the drywall.

[0013] Recognizing that heavier or low frequency speakers, such as basswoofers or subwoofers, can cause over-compression or uneven compressionof the gasket, an equally preferred alternative embodiment of theenclosure adds a spring and a spacer ring to some or all of the couplingmechanisms to resist undesirable over-compression of the gasket,particularly a lower portion thereof, thereby facilitating maintainingthe optimum or desired degree of uniform separation between thefaceplate and the drywall.

[0014] These and other important aspects of the present invention aremore fully described in the section entitled DETAILED DESCRIPTION OF APREFERRED EMBODIMENT, below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] A preferred embodiment of the present invention is described indetail below with reference to the attached drawing figures, wherein:

[0016]FIG. 1 is exploded isometric view of a preferred embodiment of thespeaker enclosure of the present invention;

[0017]FIG. 2 is a fragmentary sectional view of a portion of thepreferred speaker enclosure shown in FIG. 1;

[0018]FIG. 3 is a fragmentary sectional view of the preferred speakerenclosure of FIG. 1 wherein the faceplate is in an initial mountingposition with the isolating and insulating gasket uncompressed;

[0019]FIG. 4 is a fragmentary sectional view of the preferred speakerenclosure of FIG. 1 wherein the faceplate is in a final mountingposition with the isolating and insulating gasket compressed to providethe optimum degree of separation between the faceplate and a mountingsurface; and

[0020]FIG. 5 is a fragmentary sectional view of an equally preferredalternative embodiment of the speaker enclosure, wherein the faceplateis in a final mounting position with the isolating and insulating gasketcompressed, and a spring and a spacer ring is included to resistover-compression of the gasket, thereby facilitating maintaining theoptimum degree of separation between the faceplate and the mountingsurface.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0021] Referring to FIG. 1, a speaker enclosure 10 is shown constructedin accordance with a preferred embodiment of the present invention, andbroadly comprising a speaker box 12; a gasket 14; a faceplate 16; and aplurality of independently adjustable coupling mechanisms 18. Asdescribed in more detail below, the speaker enclosure 10 is operable tosecurely mount one or more speakers (not shown) within a wall 20,achieve an optimum degree of separation between the faceplate 16 of theenclosure 10 and a drywall surface 26 of the mounting wall 20, and toinsulate from transmitted speaker vibrations one or more wall studs 22from which the enclosure 10 depends. Although illustrated as beingmounted within a wall, the speaker box portion 12 of the enclosure 10may be mounted beneath any suitable surface or within any suitablestructure, including ceilings or floors.

[0022] The speaker box 12 protectively houses the speakers within thewall 20 and provides a mounting surface and mechanism for coupling theenclosure 10 with one or more wall studs 22. The speaker box 12 ispreferably constructed of metal, having a top, bottom, sides, back, anda speaker opening 27, and is dimensioned so as to enclose a desirednumber and size of speakers while fitting between adjacent wall studs 22and between wall sheathing 24 and interior drywall surfaces 26. Thespeaker box 12 may be mounted to the wall studs 22 in any conventionalmanner; however, a preferred manner of mounting is described in detailin pending application titled “In-Wall Speaker Mounting Apparatus”, Ser.No. 09/515,810, filed Feb. 29, 2000, hereby incorporated by reference asthough set forth in the present application.

[0023] As is best illustrated in FIG. 2, the speaker box 12 presents acircumferential lip 28 extending about the speaker opening 27. Thespeaker box 12 further includes a plurality of substantially hollowmounting pylons 30 having female receiving threads and secured to andprojecting from the back portion of the box 12. These pylons 30 form apart of the coupling mechanisms 18, which are described in more detailbelow.

[0024] Referring also to FIGS. 3 and 4, the gasket 14 operates tosuspend or isolate the faceplate 16 from the drywall 26 by ensuringoptimum separation therebetween, and to insulate the studs 22 fromtransmitted speaker vibrations. The gasket 14 is preferably heavy duty,being made of rubber or similar material, and preferably includes atubular portion 43, having an outside diameter of approximately one-halfinch, defining continuous and a collapsible air pocket 44 formaintaining isolative and insulative qualities even while undercompression. The pocket 44 is collapsible due to a plurality of spacedapart air holes 41 for allowing air to escape the pocket 44 as thegasket 14 is compressed and to reenter the pocket 44 as compression isrelieved. The gasket 14 also presents a channel 42 for receiving andclamping or crimping upon the box lip 28. Alternatively or additionally,adhesives may be used as needed or desired to permanently or removablysecure the gasket 14 to the lip 28.

[0025] An exemplary gasket is used in many automobiles to seal doors orhatches. This type of gasket is suitable because of its heavy duty,wear-resistant nature and its relatively large size. A larger-sizedgasket, particularly a larger tubular portion 43, allows for bothattachment to the recessed speaker box 12 and sufficient protrusion(approximately one-quarter inch) beyond the drywall surface 26 (assumestandard half-inch drywall thickness) to compress under pressure of theinstalled faceplate 16 while leaving an optimum degree of isolatingseparation between drywall 26 and faceplate 16.

[0026] The faceplate 16, once installed over the speaker opening 27 ofthe box 12, completes the enclosure 10. The faceplate 16 is preferablymade of an aesthetically pleasing material, such as wood, and isprovided with air ports 46 and speaker holes 47 through which individualspeakers (not shown), including tweeters, mid-rangers, and woofers, canbe mounted. The number and size of these ports and holes 46,47 is designdependent. The faceplate 16 is also provided with a plurality of holes49 for accommodating the coupling mechanisms 18, the exact number ofwhich depends upon the size of the faceplate 16, as described below.

[0027] The coupling mechanisms 18 secure the faceplate 16 to the box 12.Each coupling mechanism 18 is independently adjustable, comprising asleeve 50; a bolt 52; and on of the mounting pylons 30 mentioned above.The sleeve 50 fits into the hole 49 in the faceplate 16 and slidablyreceives the bolt 52, thereby aesthetically minimizing the bolt'sappearance and eliminating unsightly protrusion of the bolthead abovethe faceplate surface. The bolt 52 is conventional and threadablyreceived within the mounting pylon 30. It is contemplated that in someembodiments a travel limiting stop may be provided to preventovertightening the faceplate 16 to the box 12.

[0028] Because the coupling mechanisms 18 are independently adjustableand arranged about the perimeter of the faceplate 16, a substantiallyuniform degree of separation may be obtained, regardless of faceplate 16or wall 22 irregularities, or non-flush or otherwise improper speakerbox mounting. Therefore, the exact number, spacing, and location of thecoupling mechanisms 18 depends upon the size and shape of the faceplate16 as there should be a sufficient number to be spaced at reasonabledistances about the perimeter of the faceplate 16 to account for warpageor other distortion or irregularity. In the illustrated embodiment, forexample, there are shown six independently adjustable couplingmechanisms 18, with one at each corner and one midway along each longside, the result being that all coupling mechanisms 18 are spacedequidistant apart, approximately eleven inches, from one another alongthe faceplate perimeter. In general, optimum spacing will depend uponthe nature of the material, size and shape of the faceplate, and theparticular application.

[0029] Referring primarily to FIGS. 3 and 4, in operation, a hole is cutor otherwise provided in the drywall 26 so as to receive the speaker box12 and allow the box 12 to be mounted to one or more wall studs 22. Thespeaker box 12 is mounted substantially flush with the inner surface ofthe drywall 26. The gasket 14 will already have been coupled with thebox 12; the box lip 28 being received within the gasket channel 42. Thegasket 14, not being compressed, will protrude outward from the wall 20approximately one-quarter inch.

[0030] The faceplate 16 is then fitted over the box opening 27, suchthat the male bolts 52 align with the female pylons 30. The bolts 52 aretightened and adjusted independently so as to bring the faceplate 16into contact with the gasket 14, compressing the gasket 14 andcollapsing the air pocket 44 until a substantially uniform degree ofseparation between faceplate 16 and wallboard 26 is achieved, with theoptimum degree of separation being preferably {fraction (1/32)} inch, orbetween {fraction (1/64)} inch and {fraction (3/64)} inch.

[0031] Referring also to FIG. 5, an equally preferred alternativeembodiment of the speaker enclosure 110 is shown, being substantiallysimilar or identical to the embodiment described above, including thespeaker box 112; the gasket 114; and the faceplate 116. Some or all ofthe coupling mechanisms 118, however, have been adapted to accommodateheavier and lower frequency speakers, such as bass woofers andsubwoofers. More particularly, a spring 160 and a spacer ring 162 havebeen added to the coupling mechanisms 118, or, at least, to thosecoupling mechanisms 118 located on a lower portion of the speakerenclosure 110. The spring 160 fits over and about the mounting pylon130, whereafter the coupling mechanism 118 is assembled as describedabove, with the bolt 152 being threadably received within the mountingpylon 130. The spring's spring constant or rate, k, will be determinedby the weight and nature of the speaker meant to be supported; a springconstant of approximately 40 lbs/in is contemplated to be suitable formost applications, though spring constants of between approximately 5lb/in and 50 lbs/in may by used. In a preferred embodiment, the spring160 has a deflection of 0.5 in under a load of 20 lbs.

[0032] The spacer ring 162 surrounds the mounting pylon 130 and operatesto keep the spring 160 centered thereabout in its proper operatingposition. The spacer ring 162 may be constructed of foam or any othersuitable material which will resist making noise due to movement of thespring 160 thereagainst.

[0033] Just as the gasket 114 operates to adjustably suspend or isolatethe faceplate 116 above the drywall surface 126 and ensure optimumseparation therebetween, the spring 160 operates to ensure that suchsuspension and isolation is maintained when a heavier speaker is mountedwhose weight would otherwise overwhelm the gasket 114 alone. In order tofurther facilitate such suspension and isolation, a rubber washer-gasket163 may be placed between the sleeve 150 and the head of the bolt 152,thereby substantially preventing undesirable transmission of vibrationtherebetween.

[0034] When properly assembled, a first end of the spring 160 will restagainst the back portion of the speaker enclosure 112, and the other endof the spring 160 will rest against the sleeve 150. When the speakerenclosure 110 is placed in position and the bolts 152 tightened on therubber washer-gasket 163, the spring 160 will resist over-compression ofthe lower portion of the gasket 114, thereby facilitating maintaining anoptimum degree of uniform separation between the faceplate 116 and thedrywall 126.

[0035] As is also shown in the alternative embodiment of FIG. 5, themounting pylon 130 may be secured to the back portion of the speakerenclosure 112 by a countersunk bolt 153 which is screwed into a back endof the mounting pylon 130 opposite the bolt 152.

[0036] From the preceding description, it can be seen that the speakerenclosure 10 and mounting method of the present invention provide asimple and inexpensive means for suspending or isolating and insulatingfaceplate 16 and speakers from a mounting wall 20, thereby reducingdistortion, vibration, and damage. The faceplate 16 and speakers aresuspended or isolated from the wall 20 by the collapsible air pocket 44which allows the gasket 14 to compress until the faceplate 16 appears tobe flush with the wall surface but, in fact, a separation of {fraction(1/64)} to {fraction (3/64)} inch remains. Because there is no directcontact between faceplate 16 and wall 20, sound distortion is minimizedand damaging speaker vibrations are not transmitted directly to thedrywall 26. Furthermore, the faceplate 16 and speakers are insulatedfrom the mounting wall 20 by the rubber gasket 14 which tends to reducespeaker vibrations transmitted from the faceplate 16, to the speaker box12, and thereafter to the wall studs 22 or other mounting structure.

[0037] Although the invention has been described with reference to thepreferred embodiment illustrated in the attached drawings, it is notedthat equivalents may be employed and substitutions made herein withoutdeparting from the scope of the invention as recited in the claims. Forexample, as described above, the present invention is independent of anyparticular box-to-stud mounting method, though a preferred method isincorporated by reference. Furthermore, although shown as being mountedwithin a wall, the enclosure may be mounted beneath any surface orwithin any structure, such as a ceiling, floor, column, or otherstructural feature as may be desired and practical.

Having thus described the preferred embodiment of the invention, what isclaimed as new and desired to be protected by Letters Patent includesthe following:
 1. A speaker enclosure comprising: a speaker boxpresenting an opening and being mountable beneath a surface such thatthe opening is accessible through the surface; a faceplate; acompressible gasket interposed between the speaker box and thefaceplate; and a coupling mechanism adapted to adjustably couple thefaceplate to the speaker box and cause the compressible gasket tocompress, the coupling mechanism being further adapted to resistover-compression of the compressible gasket and thereby maintain asubstantially uniform degree of separation between the faceplate and thesurface.
 2. The speaker enclosure as set forth in claim 1, thecompressible gasket having a tubular cross-section defining acollapsible air pocket.
 3. The speaker enclosure as set forth in claim1, the degree of separation being between {fraction (1/64)} inch and{fraction (3/64)} inch.
 4. The speaker enclosure as set forth in claim1, the surface being a wall and the speaker box being mountable to astud within the wall.
 5. A speaker enclosure comprising: a speaker boxpresenting an opening and being mountable beneath a surface such thatthe opening is accessible through the surface; a faceplate; acompressible gasket interposed between the speaker box and thefaceplate; and a coupling mechanism including a spring and adapted toadjustably couple the faceplate to the speaker box and cause thecompressible gasket to compress, with the spring resistingover-compression of the compressible gasket and thereby maintaining asubstantially uniform degree of separation between the faceplate and thesurface.
 6. The speaker enclosure as set forth in claim 5, thecompressible gasket having a tubular cross-section defining acollapsible air pocket.
 7. The speaker enclosure as set forth in claim5, the degree of separation being between {fraction (1/64)} inch and{fraction (3/64)} inch.
 8. The speaker enclosure as set forth in claim5, the surface being a wall and the speaker box being mountable to astud within the wall.
 9. The speaker enclosure as set forth in claim 5,wherein the spring has a spring constant of between 1 lb/in and 50lbs/in.
 10. The speaker enclosure as set forth in claim 5, furtherincluding a spacer for maintaining the spring in an operating position.11. A speaker enclosure comprising: a speaker box presenting an openingand being mountable beneath a surface such that the opening isaccessible through the surface; a faceplate; a compressible gasketinterposed between the speaker box and the faceplate such that thecompressible gasket, when uncompressed, protrudes beyond the surface;and a coupling mechanism including a threaded body and a spring andadapted to adjustably couple the faceplate to the speaker box over theopening and cause the compressible gasket to compress, with the springresisting over-compression of the compressible gasket and therebymaintaining a substantially uniform degree of separation between thefaceplate and the surface.
 12. The speaker enclosure as set forth inclaim 11, the compressible gasket having a tubular cross-sectiondefining a collapsible air pocket.
 13. The speaker enclosure as setforth in claim 11, the degree of separation being between {fraction(1/64)} inch and {fraction (3/64)} inch.
 14. The speaker enclosure asset forth in claim 11, the surface being a wall and the speaker boxbeing mountable to a stud within the wall.
 15. The speaker enclosure asset forth in claim 11, wherein the spring has a spring constant ofbetween 1 lb/in and 50 lbs/in.
 16. The speaker enclosure as set forth inclaim 11, further including a spacer for maintaining the spring in anoperating position.